Volvo EX60: Megacasting, Moose-Proofing, and More! | Ars Technica Review (2026)

Volvo's new EX60 electric SUV is a game-changer in the automotive world, offering a unique blend of cutting-edge technology, innovative design, and a focus on safety that sets it apart from its competitors. Personally, I think this vehicle is a testament to Volvo's commitment to pushing the boundaries of what's possible in the EV market. What makes this particularly fascinating is the company's attention to detail and its willingness to invest in research and development, resulting in a vehicle that is not only environmentally friendly but also incredibly safe and efficient. From my perspective, the EX60 is a prime example of how automotive manufacturers can create sustainable, high-performance vehicles that cater to the needs of modern consumers.

A New Era of Electric Vehicles

The EX60 is the first model on Volvo's all-EV SPA3 platform, a scalable base upon which the company plans to build a range of other vehicles. This platform is designed specifically for EVs, and it shows in the vehicle's impressive range and charging capabilities. With up to 400 miles (643 km) of range and faster charging than any other Volvo vehicle, the EX60 is a strong contender in the EV market. What many people don't realize is that Volvo has completely changed how it builds cars for the EX60, refining every stage of production to ensure a high-quality, efficient vehicle.

Megacasting: A Modern Twist on an Ancient Concept

One of the most interesting features of the EX60 is its use of megacasting, a technique that converts molten aluminum into one lightweight piece. This process is inspired by the flying buttresses of Gothic architecture, which offer vertical and lateral reinforcement. In a modern twist on this concept, Volvo is now megacasting aluminum alloy buttress-like structures in the new EX60's diecast rear floor. This design is not only unique to the EX60 but also reduces weight, complexity, and environmental impact. The use of megacasting is a testament to Volvo's commitment to innovation and its willingness to explore new technologies.

Moose-Proofing: A Safety Feature That Sets Volvo Apart

Volvo takes moose strikes very seriously, and the EX60 is no exception. The company knows from experience that moose are serious traffic hazards, especially at dusk and dawn. To address this, Volvo moose-tests every one of its models with a life-size rubber moose crash test dummy that weighs nearly 800 pounds. This attention to safety is a key differentiator for Volvo, and the EX60 is marked with a moose Easter egg under the side mirrors as a nod to this feature. The EX60 was designed with super-strong A-pillars and a header to shield the car's occupants from potential hazards, including moose.

Smart Battery Integration and Superlative One-Pedal Driving

The EX60 will use a structural battery design akin to the one used in a BMW iX3 or a Tesla Model Y. Unlike typical EVs with heavy battery packs, the EX60's battery cells are integrated directly into its body. This design offers weight and packaging efficiency and opens up more cabin space. Most importantly for an EV, it reduces weight, which improves range. The EX60 performed beautifully with one-pedal driving, improving the car's regenerative assets. However, some may find the digital vent controls to be a bit frustrating, as they require touchscreen intervention to adjust.

A Well-Rounded Package

Overall, the EX60 is a nice combination of lessons learned from Volvo's other EVs. The automaker continues to innovate, developing new iterations of its designs that deliver real improvements. The newest model puts the puzzle pieces together in a way that shows Volvo is paying attention to the needs of modern consumers. The EX60 is a prime example of how automotive manufacturers can create sustainable, high-performance vehicles that cater to the needs of modern consumers. In my opinion, Volvo is on the right track, and the EX60 is a vehicle that will continue to push the boundaries of what's possible in the EV market.

Volvo EX60: Megacasting, Moose-Proofing, and More! | Ars Technica Review (2026)
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